526 lines
16 KiB
OpenSCAD
526 lines
16 KiB
OpenSCAD
// System to divide a Kallax half-shelf into four equal drawers
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// All units measured in millimeters
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include <../lib/mortice-and-tenon.scad>
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include <./constants.scad>
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$fn = 32;
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module sampleBox(dims, wallThickness) {
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// base
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cube([dims[0], dims[1], wallThickness]);
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// top
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translate([0, 0, dims[2] - wallThickness])
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cube([dims[0], dims[1], wallThickness]);
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// middle shelf
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translate([0, 0, (dims[2] - wallThickness) / 2])
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cube([dims[0], dims[1], wallThickness]);
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// left wall
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cube([wallThickness, dims[1], dims[2]]);
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// middle divider
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translate([(dims[0] - wallThickness) / 2, 0, 0])
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cube([wallThickness, dims[1], dims[2]]);
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// right wall
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translate([dims[0] - wallThickness, 0, 0])
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cube([wallThickness, dims[1], dims[2]]);
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}
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module tally(count, rightAlign = false) {
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groups = floor(count / 5);
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rem = count % 5;
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xAlign = rightAlign ? -(6 * groups) - (rem * 1.2) : 0;
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translate([xAlign, 0, 0])
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union() {
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if (count > 4) {
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for (i = [0: max(0, groups - 1)]) {
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translate([6*i, 0, 0]) for (j = [0:3])
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translate([j*1.2, 0, 0])
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cube([0.6, 4, 0.41]);
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translate([6*i - 0.8, 0.6, 0]) rotate([0, 0, -60]) cube([0.6, 6.2, 0.41]);
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}
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}
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if (rem != 0) {
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translate([6*groups, 0, 0])
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for (j = [0: rem - 1])
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translate([j*1.2, 0, 0])
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cube([0.6, 4, 0.41]);
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}
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}
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}
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wallThickness = 4; // Thickness of walls
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feltClearance = 2.5; // Clearance for felt pads
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// Dimensions for the box that fits inside a Kallax half-shelf
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boxWidth = kallaxSide - 2 * feltClearance;
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boxDepth = kallaxDepth;
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boxHeight = shelfHeight - 2 * feltClearance;
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drawerWidth = (boxWidth - 3 * wallThickness) / 2;
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drawerHeight = (boxHeight - 3 * wallThickness) / 2;
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tenonThickness = wallThickness * 0.6;
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//tenon([6, 8, 2.6]);
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//morticeBlank([6, 8, 2.6], 0.1);
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// Frame for the box will be made in sections to fit on the print bed
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// There are three identical horizontal layers (base, middle shelf, top) that
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// will each be made of four pieces. Looking down overhead from the Z axis they
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// are:
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//
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// x1 x2
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// ├──┴──┼─┴─┤
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// ┌─────┬───┐ ┬
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// │ C │ D │ │
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// ├─────┼───┤ ├y
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// │ A │ B │ │
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// └─────┴───┘ ┴
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//
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// There are three identical drawer sides for the lower drawers that are split
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// into two pieces. Looking from the side, along the X axis they are:
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//
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// ├───y───┤
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// ┌───┬───┐ ┬
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// │ F │ E │ ├drawerHeight
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// └───┴───┘ ┴
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//
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// There are three identical drawer sides for the upper drawers that are split
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// into two pieces. Looking from the side, along the X axis they are:
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//
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// ├───y───┤
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// ┌───┬───┐ ┬
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// │ H │ G │ ├drawerHeight
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// └───┴───┘ ┴
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x1 = boxWidth * 0.6;
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x2 = boxWidth - x1;
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y = boxDepth / 2;
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tenonDims = [6, 8, tenonThickness];
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tenonZOffset = (wallThickness - tenonThickness) / 2;
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verticalTenonDims = [6, wallThickness, tenonThickness];
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throughTenonDims = [6, 8 + wallThickness, tenonThickness];
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morticeClearance = 0.1;
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module leftSideHorizontalPiece(cutWeight = true) {
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difference() {
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cube([x1, y, wallThickness]);
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if (cutWeight) {
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union() {
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// cutouts to save materials
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translate([2*wallThickness, 2*wallThickness, -0.1])
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cube([drawerWidth - 2*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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translate([2*wallThickness, y/2 + wallThickness, -0.1])
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cube([drawerWidth - 2*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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translate([drawerWidth + 3*wallThickness, 2*wallThickness, -0.1])
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cube([x1 - drawerWidth - 5*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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translate([drawerWidth + 3*wallThickness, y/2 + 2*wallThickness, -0.1])
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cube([x1 - drawerWidth - 5*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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}
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}
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}
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}
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module rightSideHorizontalPiece(cutWeight = true) {
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difference() {
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cube([x2, y, wallThickness]);
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if (cutWeight) {
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union() {
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// cutouts to save materials
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translate([2*wallThickness, 2*wallThickness, -0.1])
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cube([x2 - 4*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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translate([2*wallThickness, y/2 + wallThickness, -0.1])
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cube([x2 - 4*wallThickness, y/2 - 3*wallThickness, wallThickness + 0.2]);
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}
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}
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}
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}
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module sidePiece(cutWeight = true) {
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union() {
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difference() {
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cube([wallThickness, y, drawerHeight]);
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if (cutWeight) {
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// cutouts to save materials
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translate([-0.1, 2*wallThickness, 2*wallThickness])
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cube([wallThickness + 0.2, y - 4*wallThickness, drawerHeight - 3*wallThickness]);
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}
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}
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if (cutWeight) {
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translate([0, wallThickness, 1.414*wallThickness])
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rotate([-41, 0, 0])
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cube([wallThickness, wallThickness, drawerHeight * 1.19]);
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translate([0, y - 2*wallThickness, 1.414*wallThickness])
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rotate([65, 0, 0])
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cube([wallThickness, wallThickness, drawerHeight * 1.97]);
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}
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}
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}
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module pieceA(cutWeight = true) {
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difference() {
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union() {
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leftSideHorizontalPiece(cutWeight);
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// tenons for joining to piece C
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translate([x1*0.2, y, tenonZOffset]) tenon(tenonDims);
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translate([x1*0.7, y, tenonZOffset]) tenon(tenonDims);
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// tenons for joining to piece B
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translate([x1, y*0.2, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90]) tenon(tenonDims);
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translate([x1, y*0.7, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90]) tenon(tenonDims);
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}
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union() {
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// mortices for joining to piece vertical pieces
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translate([tenonZOffset, y* 0.3, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([tenonZOffset, y* 0.8, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([drawerWidth + wallThickness + tenonZOffset, y* 0.3, 0])
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rotate([90, 0, 90]) morticeBlank(verticalTenonDims, morticeClearance);
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translate([drawerWidth + wallThickness + tenonZOffset, y* 0.8, 0])
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rotate([90, 0, 90]) morticeBlank(verticalTenonDims, morticeClearance);
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// piece label
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translate([2, 2, wallThickness - 0.4]) tally(1);
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}
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}
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}
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module pieceB(cutWeight = true) {
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difference() {
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union() {
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rightSideHorizontalPiece(cutWeight);
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// tenons for joining to piece D
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translate([x2*0.2, y, tenonZOffset]) tenon(tenonDims);
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translate([x2*0.7, y, tenonZOffset]) tenon(tenonDims);
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}
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union() {
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// mortices for joining to piece A
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translate([0, y*0.2, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90])
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morticeBlank(tenonDims, morticeClearance);
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translate([0, y*0.7, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90])
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morticeBlank(tenonDims, morticeClearance);
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// mortices for joining to piece vertical pieces
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translate([x2 - wallThickness + tenonZOffset, y* 0.3, 0])
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rotate([90, 0, 90]) morticeBlank(tenonDims, morticeClearance);
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translate([x2 - wallThickness + tenonZOffset, y* 0.8, 0])
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rotate([90, 0, 90]) morticeBlank(tenonDims, morticeClearance);
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// piece label
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translate([2, 2, wallThickness - 0.4]) tally(2);
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}
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}
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}
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module pieceC(cutWeight = true) {
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difference() {
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union() {
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leftSideHorizontalPiece(cutWeight);
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// tenons for joining to piece D
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translate([x1, y*0.2, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90]) tenon(tenonDims);
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translate([x1, y*0.7, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90]) tenon(tenonDims);
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}
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union() {
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// mortices for joining to piece A
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translate([x1*0.2, 0, tenonZOffset])
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morticeBlank(tenonDims, morticeClearance);
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translate([x1*0.7, 0, tenonZOffset])
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morticeBlank(tenonDims, morticeClearance);
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// mortices for joining to piece F/H
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translate([tenonZOffset, y* 0.3, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([tenonZOffset, y* 0.8, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([drawerWidth + wallThickness + tenonZOffset, y* 0.3, 0])
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rotate([90, 0, 90]) morticeBlank(verticalTenonDims, morticeClearance);
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translate([drawerWidth + wallThickness + tenonZOffset, y* 0.8, 0])
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rotate([90, 0, 90]) morticeBlank(verticalTenonDims, morticeClearance);
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// piece label
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translate([2, 2, wallThickness - 0.4]) tally(3);
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}
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}
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}
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module pieceD(cutWeight = true) {
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difference() {
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rightSideHorizontalPiece(cutWeight);
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union() {
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// mortices for joining to piece C
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translate([0, y*0.2, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90])
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morticeBlank(tenonDims, morticeClearance);
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translate([0, y*0.7, tenonZOffset])
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mirror([0, 1, 0]) rotate([0, 0, -90])
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morticeBlank(tenonDims, morticeClearance);
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// mortices for joining to piece B
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translate([x2*0.2, 0, tenonZOffset])
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morticeBlank(tenonDims, morticeClearance);
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translate([x2*0.7, 0, tenonZOffset])
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morticeBlank(tenonDims, morticeClearance);
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// mortices for joining to piece F/H
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translate([x2 - wallThickness + tenonZOffset, y* 0.3, 0])
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rotate([90, 0, 90]) morticeBlank(tenonDims, morticeClearance);
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translate([x2 - wallThickness + tenonZOffset, y* 0.8, 0])
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rotate([90, 0, 90]) morticeBlank(tenonDims, morticeClearance);
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// piece label
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translate([2, 2, wallThickness - 0.4]) tally(4);
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}
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}
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}
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module pieceE(cutWeight = true) {
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difference() {
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union() {
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sidePiece(cutWeight);
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// tenons for joining to horizontal pieces
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translate([tenonZOffset, y*0.3, 0]) mirror([1, 0, 0])
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rotate([-90, 0, 90]) tenon(verticalTenonDims);
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translate([tenonZOffset, y*0.8, 0]) mirror([1, 0, 0])
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rotate([-90, 0, 90]) tenon(verticalTenonDims);
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// tenon for joining to piece F
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translate([tenonZOffset, y, drawerHeight/2]) mirror([0, 0, 1])
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rotate([0, 90, 00]) tenon(tenonDims);
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// tenons for joining to piece G
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translate([tenonZOffset, y*0.3, drawerHeight]) rotate([90, 0, 90])
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tenon(throughTenonDims);
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translate([tenonZOffset, y*0.8, drawerHeight]) rotate([90, 0, 90])
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tenon(throughTenonDims);
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//translate([tenonZOffset, y*0.8, 0]) mirror([1, 0, 0])
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// rotate([-90, 0, 90]) tenon(verticalTenonDims);
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}
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// piece label
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translate([0.4, 2, 2]) rotate([90, 0, -90]) tally(5, true);
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}
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}
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module pieceF(cutWeight = true) {
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difference() {
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union() {
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sidePiece(cutWeight);
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// tenons for joining to horizontal pieces
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translate([tenonZOffset, y*0.3, 0]) mirror([1, 0, 0])
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rotate([-90, 0, 90]) tenon(verticalTenonDims);
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translate([tenonZOffset, y*0.8, 0]) mirror([1, 0, 0])
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rotate([-90, 0, 90]) tenon(verticalTenonDims);
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// tenons for joining to piece H
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translate([tenonZOffset, y*0.3, drawerHeight]) rotate([90, 0, 90])
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tenon(throughTenonDims);
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translate([tenonZOffset, y*0.8, drawerHeight]) rotate([90, 0, 90])
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tenon(throughTenonDims);
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}
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union() {
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// mortice for joining to piece E
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translate([tenonZOffset, 0, drawerHeight/2]) mirror([0, 0, 1])
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rotate([0, 90, 00]) tenon(tenonDims);
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// piece label
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translate([0.4, 2, 2]) rotate([90, 0, -90]) tally(6, true);
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}
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}
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}
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module pieceG(cutWeight = true) {
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difference() {
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union() {
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sidePiece(cutWeight);
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// tenons for joining to vertical pieces above
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translate([tenonZOffset, y*0.3, drawerHeight]) rotate([90, 0, 90])
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tenon(verticalTenonDims);
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translate([tenonZOffset, y*0.8, drawerHeight]) rotate([90, 0, 90])
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tenon(verticalTenonDims);
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// tenon for joining to piece H
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translate([tenonZOffset, y, drawerHeight/2]) mirror([0, 0, 1])
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rotate([0, 90, 00]) tenon(tenonDims);
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}
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union() {
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// mortices for joining to piece E
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translate([tenonZOffset, y*0.3, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([tenonZOffset, y*0.8, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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// piece label
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translate([0.4, 2, 2]) rotate([90, 0, -90]) tally(7, true);
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}
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}
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}
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module pieceH(cutWeight = true) {
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difference() {
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union() {
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sidePiece(cutWeight);
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// tenons for joining to vertical pieces above
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translate([tenonZOffset, y*0.3, drawerHeight]) rotate([90, 0, 90])
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tenon(verticalTenonDims);
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translate([tenonZOffset, y*0.8, drawerHeight]) rotate([90, 0, 90])
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tenon(verticalTenonDims);
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}
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union() {
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// mortices for joining to piece F
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translate([tenonZOffset, y*0.3, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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translate([tenonZOffset, y*0.8, 0]) rotate([90, 0, 90])
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morticeBlank(verticalTenonDims, morticeClearance);
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// mortice for joining to piece G
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translate([tenonZOffset, 0, drawerHeight/2]) mirror([0, 0, 1])
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rotate([0, 90, 00]) tenon(tenonDims);
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// piece label
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translate([0.4, 2, 2]) rotate([90, 0, -90]) tally(8, true);
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}
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}
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}
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// Mortice and tenon test pieces
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// rotate([0, 90, 0]) union() {
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// cube([10, 16, wallThickness]);
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// translate([2, 16, tenonZOffset]) tenon(tenonDims);
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// }
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//
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// translate([10, 0, 0]) rotate([0, 90, 0]) difference() {
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// cube([10, 16, wallThickness]);
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// translate([2 - 0.1, 16 - 0.1, tenonZOffset - 0.1])
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// mirror([0, 1, 0]) morticeBlank(tenonDims, morticeClearance);
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// }
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module completeBox(gap = 10, cutWeight = true) {
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// vertical layers
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for (i = [0:2]) {
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z = i * (wallThickness + 1.5*gap + drawerHeight);
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translate([0, 0, z]) pieceA(cutWeight);
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translate([x1 + gap, 0, z]) pieceB(cutWeight);
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translate([0, y + gap, z]) pieceC(cutWeight);
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translate([x1 + gap, y + gap, z]) pieceD(cutWeight);
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}
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// lower box walls
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for (i = [0:2]) {
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x = i * (wallThickness + drawerWidth) +
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(i == 2 ? gap : 0);
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translate([x, 0, wallThickness + gap]) pieceE(cutWeight);
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translate([x, y + gap, wallThickness + gap]) pieceF(cutWeight);
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}
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// upper box walls
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for (i = [0:2]) {
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x = i * (wallThickness + drawerWidth) +
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(i == 2 ? gap : 0);
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translate([x, 0, drawerHeight + 2*wallThickness + 2*gap]) pieceG(cutWeight);
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translate([x, y + gap, drawerHeight + 2*wallThickness + 2*gap]) pieceH(cutWeight);
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}
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}
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module printStack() {
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for (i = [0:2]) {
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translate([0, 0, i * (wallThickness + 0.4)]) pieceA();
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translate([0, 0, (i+3) * (wallThickness + 0.4)]) pieceC();
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translate([0, 0, (i+6) * (wallThickness + 0.4)]) pieceB();
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translate([0, 0, (i+9) * (wallThickness + 0.4)]) pieceD();
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translate([
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0,
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y + drawerHeight +throughTenonDims[1] + 4,
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i * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceE();
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translate([0,
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y + drawerHeight +throughTenonDims[1] + 4,
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(i+3) * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceF();
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translate([
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0,
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y + drawerHeight +throughTenonDims[1] + 4,
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(i+6) * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceG();
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|
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translate([
|
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0,
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y + drawerHeight +throughTenonDims[1] + 4,
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(i+9) * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceH();
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|
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}
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}
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module testStack() {
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for (i = [0:2]) {
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translate([0, 0, i * (wallThickness + 0.4)]) pieceA();
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translate([0, 0, (i+3) * (wallThickness + 0.4)]) pieceB();
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|
|
|
translate([
|
|
0,
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y + drawerHeight +throughTenonDims[1] + 4,
|
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i * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceE();
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|
|
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translate([0,
|
|
y + drawerHeight +throughTenonDims[1] + 4,
|
|
(i+3) * (wallThickness + 0.4) + wallThickness])
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rotate([90, 90, 0]) pieceF();
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|
|
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}
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}
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|
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completeBox(gap = 10, cutWeight = false);
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// testStack();
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